TManual Chapter 04

POWER TRANSFORMER - STANDARDISATION MANUAL
Chapter - 4
STANDARD MANUFACTURING QUALITY PLAN (MQP)
Working Group Members

Mr. S. K. Negi
- GETCO
Mr. M. M. Goswami
- POWERGRID
Mr. Y. V. Joshi
- GECO
Mr. Krishnan
- Mahindra Intertrade
Mr. Gautam Bhatia
- ENPAY
Mr. Baghel
- ATSA Conductors
Mr. Bharat Tolia
- Bharat Corrub
Mr. R S Thakkar
- GETCO
163
164
CHAPTER - 4
STANDARD MANUFACTURING QUALITY PLAN (MQP)
It is a contract document between customer and supplier to express commitment for delivery of transformer as per
agreed technical specification and match the type tested design.
Over a period of time as the transmission grid has grown leaps and bounds, with HVDC and 765 kV AC network,
this commitment document is gaining importance, because of rise in transformer failure rate and causing anxiety to
maintain uninterrupted supply for consumer and industry. Customer always wishes that transformer manufactured
and delivered must perform defect free service for its specified design life. It is always a challenge for supplier
(manufacturer) to keep consistency in material used and manufacturing process, which are the main cause for variation
in quality of transformer. While customer practically cannot monitor them and not expected to do so, manufacturers
are on their toes to offer cost competitive and cost effective product. The cost of material plays an important role,
considering the fact that majority of parts and components like bushing, OLTC, tank body, radiators, insulation, copper,
core material etc. are outsourced. The selection of material, its grades / type and design philosophy ultimately decide
the loss capitalization figures of final product. On the manufacturing process front, seamless integration of parts
/ components through mechanical and electrical design is the prerequisite. The change in sub-venders and skilled
manpower time to time at factory also require due diligence to control and maintain the consistency of manufacturing
process. Therefore a balanced view is needed to manufacture and deliver ideal Transformer meeting contract
specification and match type tested design.
It is evident from above background that there is need of mutually agreed manufacturing quality plan (MQP). Apart
from primary objective to have ideal transformer as per customer wish as explained above, the major benefit of MQP
would be timely delivery and any conflict shall be address upfront, so that manufacturing could take place uninterrupted
in a faithful manner. The role of design review is important to provide all necessary inputs for structuring the MQP.
It is proposed in this power transformer standardisation manual to have MQP covering following elements:
1.
Material quality and characteristics.
2.
Stage inspection of material.
3.
Stage inspection and manufacturing process.
4.
Routine and Acceptance tests.
5.
To capture Signature values .
6.
Product dimension and physical condition before dispatch.
It is equally very important that Transformer is manufactured in a dust free clean environment with humidity control.
Any compromise on this aspect will have adverse effect in expected design life of Transformer, however good is the
quality of material used.
Standard Manufacturing Quality Plan (MQP) has been designed in a manner to share the responsibility depending upon
the source of supply, testing, location and criticality of test for the performance of Transformer. Responsibility of subvendor is important for testing of raw material and components (P), but manufacturer has to play a role of verification
(V) as they have to integrate them for actual design of transformer. Similarly, responsibility of manufacturer is crucial
for routine tests (P) but customer has to actively witness (W) these tests to ensure that results are complying the
contract requirements and design review data.
165
Winding Conductor
(PICC)/ (CTC)/ Lead
wires
elongation
%
30 min
32 min
As per design requirement
Max hardness should be RF 65, when measured

in Rockwell F scale
Thickness tensile stregth

(mm)
(Nm/m2)
Up to 2.5
205-265
>2.5-5.6
205-255
As per approved drawing
For annealed conductor

0.01727 ohm/mm2 / m(max) at 20 deg
For half hard conductor
0.01777 ohm-mm2 / m (max)
Bare conductor
Width /thick (mm)
Tolerance (in mm)
Up to 3.15
0.03
3.16 to 6.30
0.05
6.31 to 12.5
0.07
12.51 to 16
0.10
> 16 mm
0.10
Insulated conductor
Covering thick(mm)
Tolerance (%)
0.25 to 0.5
-10
0.51 to 1.25
-7.5
Over 1.25
-5
Acceptable Value
W - Witness Actual testing, verify and accept
IS 7404
IS 13730
6. 0.2% Proof strength of work hardened

conductor
V - Verify and Accept
IS 7404
IS 13730
5. Hardness test
Performance
IS 7404
IS 13730
4.Tesile strength and elongation test
* Category of Responsibility: P - Actual Test
IS 13730
3. Insulation for bunched

conductor
a). No. of conductors.
b). Thickness & width of bare
conductor, Covered width &
thickness
c). Voltage test between strands
IS 1897
IS 13730
IS 7401
Reference /
Standard
IS 13730
One sample
per type per
lot
Sampling
rate
2. Resistivity at 20 deg.C
1. Visual & Dimensional check of Bare

Conductor. Thickness & width of bare
conductor, Covered width & thickness
Raw Material & Components
List of Tests
Item/Components
Sr.
No.
Sub
Vendor
Manufacturer
--
--
--
--
Customer
Category of Reponsibility*
166
Kraft Insulating
Paper
Performance
IEC 605543-1
IEC 605543-5
IEC
60554-2,
Methods of
Test
IS 7404
IS 13730
Reference /
Standard
17. Type test report
13. 0.5 to 1.0 m/Pa.s

14. 5 mN m2 /g (min)
15. 6 mN m2 /g (min)
16. 10 %
1. Paper to be smooth, unglazed surface &

free from dust particles
2. 0.8 0.05 gm/ cm3
3. Thick (m) Sub (g/cm3) Tolerence
50
40
10
65
52
05
75
60
05
90
72
05
4. 8 % max
5. 93 NM/gm (min)
6. 34 NM/gm (min)
7. NA
8. NA
9. NA
10. 1 % max
11. 6 to 8
12. 10 mS/m (max)
Thikness (mm)
Over/Upto
Corner Radius(mm)
Up to 1.0
0.50
1.01 to 1.60
0.50
1.61 to 2.24
0.65
2.25 to 3.55
0.80
3.56 to 5.60
1.00
Acceptable Value
One sample
per type per
lot
Sampling
rate
4. Moisture Content
5. Tensile Index MD
6. Tensile Index CD
7. Elongation at Break MD
8. Elongation at Break CD
9. Electric Strength in Air
10. Ash Content
11. PH of Aqueous extract
12. Conductivity of Aqueous
extract
13.Air Permeability
14.Tear Index MD
15.Tear Index CMD
16. Water Absorption (Klemn
Method)
17.Heat Stability
a.) Reduction of Degree of
Polymerization
b.) Reduction of Bursting
Strength
c.) Increase of Conductivity of
Aqueous extract.
1. Visual check & Measurement

of Thickness
2. Density
3. Substance (grammage)
7. Radius of corner of bare conductor
List of Tests
Item/Components
Sr.
No.
Manufacturer
Sub
Vendor
--
Customer
167
CRGO Laminations
Performance
IS 3024
Losses as per grade of CRGO lamination used
One sample
from
offered lot
1. Visually defect free, as per design

requirement
2. Less than 2 micron burr
3. As per IS 649
4. 10 cm2 min average
05 cm2 min individual
5. 4 % max increase in specific measured loss
6. As per table no. 4 of IS 3024
As per approved design
IS 3024
IEC 60404
ASTM 4343
Each Lot
One sample
per lot
Acceptable Value
Reference /
Standard
Sampling
rate
7. Test for specific Watt loss test
5 Aging test (type test)

6. Test on stacking factor
2. Cutting Burr
3. Bend / Ductility test
4. Surface insulation resistivity check
Check following documents

(a) Invoice of Supplier
(b) Mills Test certificate
(c) Packing List
(d) Bill of Lading
(e) Bill of Entry
Check points:
1. Visual, Dimension & Thickness
List of Tests
Item/Components
Sr.
No.
--
Manufacturer
Sub
Vendor
--
Customer
168
Pre-compressed
Press Board
Performance
PD--> Perpendicular Direction
One sample
of each size
per lot
Sampling
rate
IEC 606413-1
IEC
60641-2,
Methods of
Test
Reference /
Standard
(2) Up to 1.6 mm TK -1.0-1.2

>1.6-3 mm TK -1.1-1.25
>3-3.6 mm TK -1.15-1.30
>6-8 mm TK -1.2-1.3
(3) Up to 1.6 -10 %; >1.6-3 mm - 7.5 %
>3-3.6 mm - 5 %; >6-8 mm TK -4 %
(4) Up to 1.6 -45 %; >1.6-3 mm - 50 %
>3-3.6 mm - 50 %; >6-8 mm TK -50 %
(5) Up to 1.6 mm TK -11 min
> 1.6-3 mm TK - 9 min
> 3 - 3.6 mm TK -7 min
> 6-8 mm TK - 7 min
(6) 6 % max
(7) MD - 0.5 % max, CD- 0.7 % max, Thick -5
% max
(8) 6-9 for solid boards
(9) Up to 1.6 - 5 max (mS/m)
> 1.6-3 mm - 6 max, > 3-3.6 mm - 8 max
> 6-8 mm TK - 8-10 max
(10) Up to 1.6 - 12 kV/ mm
> 1.6-3 mm - 11 kV/mm
> 3-3.6 mm - 10 kV / mm
> 6-8 mm TK - 9 kV/mm
(11) Up to 1.6 - 40 kV/ mm
> 1.6-3 mm - 35 kV/mm
> 3-3.6 mm - 30 kV / mm
> 6-8 mm TK - 30 kV/mm
(12) 1 % maximum
MD CD
(13) Up to 1.6 - 3 % 4 %
>1.6-3 mm - 3 % 4 %
>3-3.6 mm - 3 % 4 %
>6-8 mm TK -3 % 4 %
(1) No surface defects
Acceptable Value
CD--> Cross Direction
14. Tensile strength MD, CD

15. Ply Bond Resistance
16. Flexural strength MD, CD (Laminated
Boards)
13. Elongation MD, CD
12. Ash Content
11.Electric Strength in Oil
10. Electric Strength in Air
8. pH of aqueous extract
9.conductivity of aqueous extract
6. Mositure Content
7. Shrinkage MD, CD & PD
5. Oil Absorption
4. Reversible part Compressibility
3. Compressibility C
1. Visual & dimensional check, thickness,

width & length/.
2. Apparent Density
List of Tests
***TC --- Test Certificate
Item/Components
Sr.
No.
Sub
Vendor
V
Manufacturer
V
Customer
169
Permawood
Porcelain Bushings
(Hollow)
Polyster Resin
Impregnated Glass
Fibre Tape
Synthetic Rubber
Bonded Cork sheet
(SRBC)
Performance
IS 4253
IS 15208
1. Free from surface deffect

2. 70 10 IRHD
3. 85 % max
4. NA
5.1550 kpa (min)
6. Should be satifactory when bent though
1800 round the material of diameter three
times the thickness of specimen.
7. 25-35 %
8. 80 % min
9. Change in volume 15 % max for 70 hours at
100 deg c in oil
10. 5-8.5
1. Free from visual defect

2. 12 months
3. 0.25 to 0.35 mm ( 0.07)
4. 20 to 50 mm ( 2)
5. Min 200 N/mm
6. 27 ( 3%)
7. Max 200 C
1. As per approved drawing.

2. As per IS 2099
2. 0.8 to 1.3 gm/cc

3. Max 7%
4. Min 5%
5. Min 60 KV
6. Min for LD - 700 KV /cm2
9. Thikness (mm)
Tolerance (+/- mm)
10 to 25
1.2
26 to 50
1.4
51 to 150
2.0
1. Shall be free from surface defect
Acceptable Value
One sample
per lot
Each lot
As per IS/
IEC
IS 2099
IS 3513
IS 1708
IS 1736
IS 1998
One sample
of each size
per lot
100%
Reference /
Standard
Sampling
rate
7. Compressibility
8. Recovery
9. Aging in Oil-Finish, Flexibility & change
in volume
10. Ph value
1. Visual check, thickness, length, width

2. Hardness
3. Compression set
4. Side flow under compression
5. Tensile strength
6. Flexibility
1. Visual Check
2. Verification of shelf life
3. Thickness
4. Width
5. Tensile Strength
6. Resin Content
7. Softening point of resin
1. Visual & dimensional check.

2. Power frequency voltage withstand test
1. Visual & dimensional check, thickness,

width & length.
2. Density
3. Moisture content
4. Oil Absorption at 90 C
5. Electric Strength at 90 C
6. Tensile strength
7. Compressive strength test
8. Shear strength age-wise
9. Thickness
List of Tests
Item/Components
Sr.
No.
Sub
Vendor
Manufacturer
--
--
--
--
Customer
170
Condenser Bushing
Buchholz Relay
Bimetallic Terminal
Connector
Marshalling Box
Remote Tap
Changer Control
Cabinet
10
11
12
13
Performance
1. Dimension & Visual Check

2. 2kV test for Auxillary wiring
3. Paint shade & Thickness
4. Wiring routing check
5. Functional Check
6. Verification of BoQ
1. Dimension & Visual check

2. 2kV test for Auxillary wiring
3. Paint shade & Thickness
4. Wiring routing check
5. Functional Check
1. Dimensional
2. Visual check
3. Tensile strength
4. Resistance
7. Loss of oil & Surge test
IS 3637
100%
100%
100%
1. As per approved drawing

2. 1 min withstand
4. Firm and aesthetic

2. 1 min withstand
4. Firm and aesthetic

2. Free form defects
3. As per type test report
4. As per type test report

2. No leakage
3. 2 KV for 1 min. withstand
4. Min 10 M by 500 V DC megger
5. No leakage at 1.75 Kg/cm2 oil pressure for
15 mins
6. GOR - 1: 90 to 165 CC
GOR - 2: 175 to 225 CC
GOR - 3: 200 to 300 CC
7. GOR - 1: 70 to 130 CC
GOR - 2: 75 to 140 CC
GOR - 3: 90 to 160 CC
3. As per IEC - No flash-over/ puncture

4. No leakage
5. No leakage
6. As per approved GTP
1. Tan Delta - 66 kV - 0.7%

Above 66 kV - 0.4%
2. As per approved GTP
Acceptable Value
Approved
drawing
and specification
Approved
drawing
and specification
IS 5561
IS 2099
IEC 60137
100%
100%
Reference /
Standard
Sampling
rate
6. Gas volume test at 5 ascending towards

conservator
1. Type & make

2. Porosity
3. High voltage
4. Insulation resistance
5. Element test
Routine Test
(1) Measurement of dilectric dissipation
factor and capacitance
(2) Dry power frequency voltage withstand
test
(3) Measurement of partial discharge
(4) Pressure test
(5) Tightness test
(6) Creepage distance
(7) Visual & dimensional check
List of Tests
Item/Components
Sr.
No.
--
--
--
--
W
----W
W
P
V
V
V
V
V
V
Customer
Manufacturer
Sub
Vendor
171
Air cell (Flexi Air

Separator)
Roller Assembly
Oil & winding

Temperature
Indicator
Pressure Relief
Device
Magnetic Oil Level

Gauge (MOG)
Valves
Transformer Oil
14
15
16
17
18
19
20
Performance
Routine Test as per IS 335
1. Type, make & Visual

2. Leakage test/ Seepage test
100%
100%
As per IEEMA specification (see Chapter 6)
1. As per approved drawing & free from defect

2. No leakage

2. Check pointer position for Max, Min and
center level
3. Withstand for 1 minute
4. No leakage at 4 kg/cm2
5. Operate at Min level indication

2. No leakage
3. Satisfactory operation at pressure release
4. 2 kV withstand for 1 min
IS 335
IEC 60296
IS 778
--
IS 2500
100%
100%
--
100%

2. 1.5% of FSD
3. Withstand for 1 min
4. operation within 2 C of setting
1. Free from surface defect

2. For shaft as per MS EN8, BS 970-1
For roller wheel of cast iron IS 210
For roller wheel of Cast steel IS 1030
IS 8500
One sample
per melt/
heat
treatment
batch
Acceptable Value
1. As per approved deawing

2. No leakage for 24 hours
3. No deformation
Reference /
Standard
IS 3400
100%
Sampling
rate
1. Type & make

2. Dial Calibration for level
3. 2kV HV test for 1 min between
all terminal & earth
4. Leak test
5. Switch/contact operation test
1. Type & Make

2. Operating air pressure
3. Switch/contact testing
4. HV test
1. Type & make

2. Calibration
3. 2kV HV test for 1 min between
all terminals & earth
3. Switch contact operation test
1. Visual & Dimensions.

2. Mech. Properties & Chemical
composition of raw material used for
shaft & roller forging
1. Make, Visual & Dimensions

2. Pressure test at 0.105 Kg/cm2
3. 10 times inflation and deflation test at
0.105 Kg/cm2
List of Tests
Item/Components
Sr.
No.
Manufacturer
Sub
Vendor
--
--
--
--
--
--
Customer
172
Tank & Accessories
Radiators
OLTC
21
22
23
Performance
100%
3. Pressure test on divertor switch oil

compartment
4. Mech. Operation test
5. Sequence test
6. Visual & Dimentional check
7. Operational test on Surge relay
1. Auxiliary circuit insulation test at 2kV for

1min.
2. Function test on OLTC
100%
one per
design
6. Tank 6.1 Presseure test

6.2 Vaccum test
1. DP test on lifting lugs

2. Surface cleaning of header
support and bracing details by
sand/shot blasting
3. Air pressure test on elements
4. Dimensional check after final
welding
5. Air pressure test on radiator
assembly
6. Visual check of paint shade,
paint film thickness & film
adhesion
CBIP
manual
2013
100%
1. Check for a fit up for butt

welds on tank walls, base &
cover
2. DP test on Butt welds after fit
up & load bearing welds
3. Visual & Dimensional check
after final welding
4. Air leakage test on assembled tank with
turrets & on conservator
5. Visual check of paint shade,
paint film thickness & film
adhesion
4. Satisfactory operation for 1 complete cycle

5. Switching time within permissible limit
6. Free from defects
7. Satisfactory working of trip & reset
2. Satisfactory working as per drawing

approved
3. No leakage
1. To Withstand for 1 min
6. As per tech spec, coating thickness more

than 70 micron
5. 2 kg/cm2 for 30 minutes - no leakage
3. As per relevent standards /CBIP

1. No welding defect
2. Free from surface defect
6.1) Twice the normal head + 30 KN/m2 for 1 hr.

Withstand
6.2) 760 mm of Hg for 1 hr. withstand
5. Paint thickness
Outside: 155 micron
Inside : 30 micron
No peel-off
4. No leakage
3. Free from defect
2. Check for proper welding
1. Check for proper welding
Acceptable Value
IEC 60214
IEEMA
standard
CBIP
manual
2013
Reference /
Standard
Sampling
rate
List of Tests
Item/Components
Sr.
No.
Manufacturer
Sub
Vendor
--
Customer
173
Cooling Fans
Nitrile Rubber
Gasket
Bushing CT
Remote
Temperature
detector
Oil pump
24
25
26
27
28
Performance
2. HV test
3. Oil pressure test
4. Locked rotor test
1. No load test
IS 2705
100%
100%
1. Satisfactory performance & no load losses

within limit
2. 2 kV AC for 1 min withstand
3. 5 Kg/cm2 at 90 C for 30 mins withstand
4. Statisfactory operation of protection
1. 500 V AC for 1 min withstand

2. 1% of FSD
3. 10 M min with 500 V DC megger
3. Rated current withstand for 1 min

4. As per IS 2705
5. 3 kV AC for 1 min withstand

2. As per IS 2705
1. Within tolerance
2. 70 5 IRHD
3. 12.5 N/mm2 min
4. 20% max
5. 250% min
6. Max change in harness - 10 IRHD
7. Change in weight - 5 to 8.5%
Change in thickness - 4% max
Change in width & length - 0.2% max

3. 1.3 kV for 1 min or 1.8 kV for 5 sec
4. 10 M min with 500 V DC megger
Acceptable Value
--
--
BS 2751
1 sample/
Lot
100%
IS 2312
Reference /
Standard
100%
Sampling
rate
1. HV test
2. Calliberation accuracy check
3. IR value
1. Dimensions
2. Verification of terminal
marking & polarity
3. Overvoltage inter-turn test
4. Determination of error
5. HV Test
1.Dimensions
2.Shore Hardness
3.Tensile Strength
4.Compression set test
5. Elongation at break
6. Accelerated aging in air
7. Accelerated aging in oil
1. Type & Make

2. Power consumption, rating test
3. HV test
4. Insulation resistance value
List of Tests
Item/Components
Sr.
No.
Manufacturer
Sub
Vendor
--
--
--
--
Customer
174
One sample of
each type
One sample of
each type
One sample of
each type
Dimensional check
Check for burr
Edge bow
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
Core Diameter
Leg Centre & Leg length
Assembly of limb Insulation

& plates
Rectangularity of Core
Assembly
Check for Overlaps & air gap

at joints
Leaning of Core
Earthing of Core
Limb Clamping & Binding
Insulation test between core

& core clamp / frame
Loss measurement on built

up core assembly.
Visual check for drum lable

and Conductor Size
100%
100%
Total stack height
Winding
100%
Visual check
Core Building
One sample of
each type
Lamination for core
Visual check
In Process Inspection No of turns / disc
Sampling rate
Item/Process
Sr.
No.
As per design drawings
As per specification / GTP
As per specification
Design drawing
Design drawing
Design drawing
Design drawing
Design drawing
Design drawing
--
IS 3024
--
--
--
Reference / Standard
Within limit as per design
Within limit as per GTP
shall withstand 2 kV for 1 min
Proper connection
No leaning
As per design
As per design
As per design
within specified tolerence of design
Free from defect
As per IS 3024
Less than 20n
Prime CRGO and Free from defect
Acceptable Value
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
Sub Vendor
Manufacturer
Customer
175
100%
100%
Continuity test
Inter-turn Insulation
100%
100%
100%
100%
100%
100%
100%
100%
Lead & coil indentification &

marking
Brazing / Crimping of Joints
Visual chek for completeness

and cleanliness
Ratio test
Magnetic balance test
Magnetizing current test
Alignment of Spacers/Blocks
HV test
Performance
100%
Visual check for intercoil

insulation
Core Coil Assembly
100%
Mfgrs standard
--
2 kv for 1 min withstand
Aligned
Tolerance as per standards
Complete assembly shall be free from dust/

particles
Shall be smooth and no sharped age
As per design
As per design
As per design
No breaking of continuity
As per design
As per design
As per design
As per approval
As per approval
As per Factory drawing
As per Factory drawing
Acceptable Value
As per IS 2026 / IEC 60076
As per IS 2026 / IEC 60076
As per IS 2026 / IEC 60076
--
--
--
--
--
100%
Lead & coil indentification &

marking
As per brazing procedure
Insulation arrangement
100%
Visual inspection of brazed

joints
Customer approval
--
Brazing procedure and

brazer's qualification
As per approved drawings /

Factory drawing
As per approved drawings /

Factory drawing
Visual check for transposition 100%
100%
Dimensional checks
i) Outer diameter
ii) Inner diameter
iii) Unshrunk height
iv) Radial thickness
100%
Sampling rate
Nos of discs
No of turns / disc
Item/Process
Sr.
No.
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
Sub Vendor
Manufacturer
Customer
176
100%
100%
100%
100%
Check for clearance from

tank walls
Visual checks for crimped

joint
Visual checks for bushing CT

assembly tightness
Ratio test
100%
100%
100%
Dimensions
Pressure test
Vacuum test
100%
Checks for complete

tightness before tanking
a) Tightness of all joints /
screws
b) Application of thread
locking adhesive
c) Padding of top yoke
d) Pressing of active parts
e) Fitting of wall shunts &
packing
Performance
100%
Drying
Ovening, Tanking and Oil filling
100%
Thickness of walls
Tank
100%
Check for cable sizes
100%
OLTC fitting & connections
Connections and checks before tanking
Sampling rate
Item/Process
Sr.
No.
Manufacturer standard
As per CBIP
As per CBIP
As per design
Low voltage tan delta and PI values shall

be checked periodically and after achieving
the satisfactory values the process will be
declared complete
To withstand, permenat deflection shall not

exceed as per specification
To withstand, permenat deflection shall not

exceed as per specification
As per approved drawings
Assembly tightness
Shall be smooth and no sharped age
As per design
As per design
Acceptable Value
As per IS 2026 / IEC 60076
--
--
--
--
--
--
--
--
--
--
--
--
--
--
Sub Vendor
Manufacturer
---
Customer
177
100%
100%
100%
Check for oil qualtity before

impregnation
Oil filling & Air release
Impregnation process
Performance
100%
2 kV HV test between
(i) Core & end frame
(ii) Core & yoke bolts
(iii) End frame and yoke bolts
100%
Tanking of active parts and

check for clearance from
tank walls
100%
Cleanliness of tank before

tanking
Sampling rate
Item/Process
Sr.
No.
Sufficient impregnation time shall be given

before conducting the electrical test on the
transformer
To withstand 2 kV for 1 min
As per design
Shall be clean.
Acceptable Value
--
--
--
--
--
--
Sub Vendor
Manufacturer
---
---
---
Customer
178
Impedance between each pair of winding /

Impedence Voltage
Excitation losses at 90, 100 and 110 % rated

voltage measured by the average voltmeter
method
Positive phase sequences impedance

measurement on three phase transformers
Regulation at rated load and unity, 0.9, 0.8 lagging

P.F.
Load losses, measured at rated frequency, by

applying a primary voltage sufficient to produce
rated current in the windings with secondary
windings short circuited
Separate source voltage with stand test.
Induced over voltage with stand test
Auxiliary losses (fans. Pumps etc.)
SFRA test
Zero Sequence impedance test
Tests on tap-changer (IEC:214)
Tan delta & capacitance measurement test for

bushings and windings
Tests on transformer oil including DGA on selected

sample as per IS:9434/IEC:567, before and after
temp rise test and at final stage before dispatch.
Corrosive sulphur detection test as per ASTM
D1275 subjecting oil for 150oC for 48 hrs.
10
11
12
13
14
15
16
Acceptable Value
IS:2026 / IEC 60076 As per applicable

/ specification
standard
100%
Sampling rate
Polarity and phase relationship (Vector group)
Performance
Turn ratio for all sets of windings on each tap, with

percentage error / Voltage
Resistance of each winding.
Routine Tests
Description of Test
IS:2026 / IEC 60076 / specification
Test
As per applicable standard
Sr. No.
W
W
W
P
P
P
Customer
Manufacturer
179
HV withstand test on auxiliary equipments and

wiring
Measurement of Insulation Resistance
Measurement of acoustic noise level
Measurement of harmonics of no load current
Measurement of Partial Discharges of transformer
Measurement of no load current with 415 V AC

supply on LV side.
Tests on air cell
ACLD test (For 220 kV class transformer)
Moisture content in active part measurement test
20
21
22
23
24
25
26
27
28
Short circuit withstand capability test (Optional)
Tests on OLTC
IEC 60214
IS:2026 / IEC 60076
CBIP manual
IS:2026 / IEC 60076
IS:2026 / IEC 60076
Acceptable Value
As per standards
As per standards
Permanent
deflection within
limit as per length
of plate used.
As per standards
As per standards
0.5 % max
One from Lot or as

agreed between
Manufacturer and
Purchaser.
Vacuum and pressure test on tank
Performance
Lightning Impulse Voltage withstand test with

chopped wave
Switching Impulse Voltage withstand test
Temperature rise test
Type Tests
Magnetic Balance & current test on all winding
19
Tank leak test at 5 psi (35 kN/m2) for 12 hrs with

oil & 1 hr with air.
18
Sampling rate
IS:2026 / IEC 60076 / specification
Description of Test
Test
Sr. No.
As per applicable standard
Customer
Manufacturer
180
Short Time Current withstand test on offered HV

and LV terminal connectors for 40 kA for 3 Sec for
220 kV & 132 kV Class and 25 kA for 3 sec for 66
kV & below class
Verification of completeness of accessories
Bushings
Conservator tank
Transformer oil
Check Nitrogen / dry air pressure after filling
Mesurement of dew point of nitrogen or dry air

before and after filling in tank before dispatch
Check proper blanking of all openings and leakage, 100%

if any
Provision of Impact recorder / tracking system
Check for soundness of packing
10
11
Performance
Radiators
Acceptable Value
IS:5561
IS:2026 / IEC 60076
0.15 to 0.2 kg/

cmsq above ATM
Pr
--
--
IS 13947/IEC 60529: -2001
100%
100%
100%
100%
100%
100%
100%
100%
100%
Pipes and headers
100%
Sampling rate
Packing & Dispatch - Main tank
Measurement of transferred surge in LV due to

Lightning impulse on HV & LV
Degree of protection (IP55) for control cabinets

& RTCC panel, OLTC driving mechanism, terminal
boxes of PRV, MOG, Buchholz Relay, pump motors,
fans etc
Special Tests (Optional)
Description of Test
Manufacturers Standard
Test
Manufacturers Standard
Manufacturers
Standard
Sr. No.
--------
P
P
P
P
P
P
P
--
--
--
--
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Customer
Manufacturer
181
182

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POWER TRANSFORMER - STANDARDISATION MANUAL

Working Group Members

Mr. Gautam Bhatia

Mr. Bharat Tolia

POWER TRANSFORMER - STANDARDISATION MANUAL

POWER TRANSFORMER - STANDARDISATION MANUAL

Material quality and characteristics.

Stage inspection of material.

Stage inspection and manufacturing process.

Routine and Acceptance tests.

To capture Signature values .

Product dimension and physical condition before dispatch.

As per design requirement

Max hardness should be RF 65, when measured

Thickness tensile stregth

As per approved drawing

For annealed conductor

W - Witness Actual testing, verify and accept

6. 0.2% Proof strength of work hardened

V - Verify and Accept

4.Tesile strength and elongation test

* Category of Responsibility: P - Actual Test

3. Insulation for bunched

1. Visual & Dimensional check of Bare

Raw Material & Components

17. Type test report

13. 0.5 to 1.0 m/Pa.s

1. Paper to be smooth, unglazed surface &

W - Witness Actual testing, verify and accept

V - Verify and Accept

1. Visual check & Measurement

7. Radius of corner of bare conductor

* Category of Responsibility: P - Actual Test

POWER TRANSFORMER - STANDARDISATION MANUAL

Losses as per grade of CRGO lamination used

W - Witness Actual testing, verify and accept

1. Visually defect free, as per design

As per approved design

V - Verify and Accept

7. Test for specific Watt loss test

5 Aging test (type test)

Check following documents

* Category of Responsibility: P - Actual Test

PD--> Perpendicular Direction

V - Verify and Accept

(2) Up to 1.6 mm TK -1.0-1.2

(1) No surface defects

W - Witness Actual testing, verify and accept

CD--> Cross Direction

14. Tensile strength MD, CD

13. Elongation MD, CD

12. Ash Content

11.Electric Strength in Oil

10. Electric Strength in Air

4. Reversible part Compressibility

1. Visual & dimensional check, thickness,

* Category of Responsibility: P - Actual Test

***TC --- Test Certificate

POWER TRANSFORMER - STANDARDISATION MANUAL

1. Free from surface deffect

1. Free from visual defect

1. As per approved drawing.

2. 0.8 to 1.3 gm/cc

1. Shall be free from surface defect